Protecting catalytic activity of a SAPO molecular sieve

ABSTRACT

This invention is directed to a method of making an olefin product from an oxygenate feedstock and a method of protecting catalytic activity of a silicoaluminophosphate molecular sieve. The methods comprise providing a silicoaluminophosphate molecular sieve having catalytic sites within the molecular sieve; shielding the catalytic sites to protect from loss of catalytic activity; and contacting the protected sieve in its activated state with an oxygenate feedstock under conditions effective to produce an olefin product before undesirable loss of catalytic activity. Undesirable loss in catalytic activity occurs when activated molecular sieve contacting the oxygenate feedstock has a methanol uptake index of at least 0.15.

RELATED U.S. APPLICATION DATA

This application is a continuation of Ser. No. 10/206,574, filed Jul.26, 2002, and now U.S. Pat. No. 6,797,852, which is a divisional of Ser.No. 09/760,289, filed Jan. 12, 2001, now U.S. Pat. No. 6,455,748, whichis a divisional of Ser. No. 09/391,770, filed Sep. 8, 1999, now U.S.Pat. No. 6,316,683, which claims the benefit of U.S. ProvisionalApplication No. 60/137,933, filed Jun. 7, 1999, the disclosures of whichare incorporated herein by reference in their entireties.

FIELD OF THE INVENTION

This invention relates to a method of protecting the catalytic activityof a SAPO molecular sieve, and to a method of making an olefin productby contacting the activated catalyst with an oxygenate feedstock. Inparticular, this invention relates to a method of protecting thecatalytic activity of a SAPO molecular sieve by shielding the catalyticsites of the molecular sieve.

BACKGROUND OF THE INVENTION

Silicoaluminophosphates (SAPOs) have been used as adsorbents andcatalysts. As catalysts, SAPOs have been used in processes such as fluidcatalytic cracking, hydrocracking, isomerization, oligomerization, theconversion of alcohols or ethers, and the alkylation of aromatics. Inparticular, the use of SAPOs in converting alcohols or ethers to olefinproducts, particularly ethylene and propylene, is becoming of greaterinterest for large scale, commercial production facilities.

As is known in the development of new large scale, commercial productionfacilities in the commodity chemical business, many problems arise inthe scale up from laboratory and pilot plant operations. This isparticularly a concern in catalytic reaction systems where large scaleoperation will be several orders of magnitude larger than typical pilotscale facilities. For example, conventional laboratory scale processesof making olefin products from oxygenate feed are conducted withcatalyst loads of about 5 grams. Conventional large pilot plantoperations may utilize as much as 50 kg of catalyst, making on the orderof 20 kg/hr ethylene and propylene product, but this is neverthelessminuscule in comparison to what a large scale, commercial productionfacility would produce, if one were in existence today. It would bedesirable to operate large scale, commercial production facilities,which may require a catalyst loading of anywhere from 1,000 kg to700,000 kg, producing anywhere from 600 to 400,000 kg/hr of ethylene andpropylene product, if a reliable method of providing such a largequantity of catalyst could be used.

Operating large scale, commercial production facilities clearly presentsgreat challenges in the development of the catalyst production-to-usechain. By production-to-use chain is meant the entire area of activitiesbeginning with the production of molecular sieve, including suchactivities as receipt of starting materials, on through thecrystallization process. Also included in the production-to-use chainare intermediate activities which include formulation of the sieve withbinders and other materials, activation of the manufactured sieve andfinished catalyst; storage, transport, loading, unloading of molecularsieve and finished catalyst; as well as other practices associated withthe handling and preparation of the sieve and finished catalyst for itsultimate use. The production-to-use chain ends at the point when themolecular sieve is introduced into the reaction system. For purposes ofthis invention, the end of the production-to-use chain does notnecessarily mean the instant when the molecular sieve is introduced intothe reaction system, since large scale systems are very large andinstantaneous measurements are not practically feasible. In large scalesystems, the production-to-use chain may be considered as completed sometime within 12 hours of loading an activated catalyst into the reactionsystem.

Since information to date relating to production of olefin products bycatalytic conversion of oxygenate feedstock has been limited tolaboratory and small pilot plant activities, little if any attention hasbeen paid to the problems associated with the intermediate activities inthe production-to-use chain. For example, little attention has beenfocused on the impact of storage, transport, etc. on catalyst activity,since small scale activity is rather easily manageable. While today onlyrelatively small quantities of catalyst are stored and transported,large quantities of materials will need to be handled for commercialoperations. This may require storage of large quantities of sieve andcatalyst materials for considerable periods of time, at multiplelocations, and under rather rigorous industrial conditions.

As the management of sieve and catalyst in the catalystproduction-to-use chain expands in volume and complexity, there is thelikelihood that millions of dollars will be tied up in catalystinventory, and the value of the sieve and catalyst will be lost ifquality is not maintained at every step. Loss of quality willnecessarily translate to loss of product quality as well as loss ofproduct quantity, and these product losses could far outweigh the costof the sieve and catalyst.

Although there has been some work published relating to the intermediateactivities in the catalyst production-to-use chain, few of the problemsassociated therewith have been addressed. For example, U.S. Pat. No.4,681,864 to Edwards et al. discuss the use of SAPO-37 molecular sieveas a commercial cracking catalyst. It is disclosed that activatedSAPO-37 molecular sieve has poor stability, and that stability can beimproved by using a particular activation process. In this process,organic template is removed from the core structure of the sieve justprior to contacting with feed to be cracked. The process calls forsubjecting the sieve to a temperature of 400-800° C. within thecatalytic cracking unit.

U.S. Pat. No. 5,185,310 to Degnan et al. discloses another method ofactivating silicoaluminophosphate molecular sieve compositions. Themethod calls for contacting a crystalline silicoaluminophosphate withgel alumina and water, and thereafter heating the mixture to at least425° C. The heating process is first carried out in the presence of anoxygen depleted gas, and then in the presence of an oxidizing gas. Theobject of the heating process is to enhance the acid activity of thecatalyst. The acid activity is enhanced as a result of the intimatecontact between the alumina and the sieve.

Briend et al., J. Phys. Chem. 1995, 99, 8270-8276, teach that SAPO-34loses its crystallinity when the template has been removed from thesieve and the de-templated, activated sieve has been exposed to air.Data are presented, however, which suggest that over at least the shortterm, this crystallinity loss is reversible. Even over a period ofperhaps two years, the data suggest that crystallinity loss isreversible when certain templates are used.

EP-A2-0 203 005 also discusses the use of SAPO-37 molecular sieve in azeolite catalyst composite as a commercial cracking catalyst. Accordingto the document, if the organic template is retained in the SAPO-37molecular sieve until a catalyst composite containing zeolite and theSAPO-37 molecular sieve is activated during use, and if thereafter thecatalyst is maintained under conditions wherein exposure to moisture isminimized, the crystalline structure of the SAPO-37 zeolite compositeremains stable.

As seen from the disclosure herein, we have now found that an activatedSAPO molecular sieve will exhibit a loss of catalytic activity whenexposed to a moisture-containing environment, and that this loss occursbetween the time the catalyst is activated and even after as little asone day of storage. More importantly, we have now found that the loss ofcatalytic activity is not reversible after a certain period of time. Itis desirable, therefore, to obtain an activated SAPO molecular sieve andincorporate that molecular sieve into a catalytic process before loss ofcatalytic activity becomes too great.

SUMMARY OF THE INVENTION

In order to overcome at least one of the many problems inherent in theprior art, the invention provides a method of protecting catalyticactivity of a silicoaluminophosphate molecular sieve which is to be usedin converting an oxygenate feedstock to an olefin product, particularlyan olefin product comprising ethylene, propylene, or both. Protectionagainst loss of catalytic activity is provided by covering catalyticsites of the molecular sieve with a shield prior to contacting with theoxygenate feedstock. Catalytic contact, i.e., contact of feedstock withmolecular sieve under catalytic conversion conditions, must be madebefore a parameter defined herein as the methanol uptake index drops toolow. In addition, the weight percent methanol conversion of thecatalyst, determined at standard parameters, should not be allowed todrop below a minimum percentage. Drops in methanol uptake index ormethanol conversion which are too low will likely result in a catalystthat is of little or no practical use in a large scale process.

In this invention, the shield can be provided in several ways. Theshield can be the template material which is actually used to make themolecular sieve. As is known in the art, the template forms the porousstructure within the molecular sieve. Conventionally, the template isremoved by calcining, essentially burning it from the molecular sieve.Leaving the template within the intracrystalline structure for theproper time will, however, protect the catalytic sites that are withinthe porous structure of the molecular sieve.

Even if the template is removed the molecular sieve can still beprotected by providing other types of shields to cover the catalyticsites. For example, carbonaceous material can be used as a shield. Oneway of providing the carbonaceous material is to partially calcine orburn the template, leaving enough carbon material within the pores ofthe molecular sieve to provide the shield.

An anhydrous environment can also act as a shield, even when thetemplate or carbonaceous material has been removed. An anhydrousenvironment is one that is depleted in water content. It can be either agas or a liquid environment.

In a particular embodiment of protecting catalytic activity of asilicoaluminophosphate molecular sieve, the invention comprisesproviding a silicoaluminophosphate molecular sieve having catalyticsites protected against loss of catalytic activity by covering with ashield, and introducing the molecular sieve into an oxygenate reactionsystem, wherein the molecular sieve has a methanol uptake index of atleast 0.15 at time of contact with oxygenate under conditions effectiveto convert the oxygenate to olefin product. To provide protection forstorage and transporation the shield should be provided within themolecular sieve for at least 12 hours prior to contact with oxygenate.Longer storage and transporation conditions may require that the shieldbe provided within the shield for longer periods of time, e.g., 24hours, 1 month, or perhaps many months.

The protected molecular sieve is of great benefit in large scalecommercial processes of making olefin product from oxygenate feedstock,particularly making olefins containing ethylene or propylene fromfeedstock comprising methanol or dimethyl ether. In a particularembodiment of making an olefin product from an oxygenate feedstock, theinvention is to a method which comprises providing asilicoaluminophosphate molecular sieve having catalytic sites within themolecular sieve; providing a shield to protect the catalytic sites fromcontact with water molecules; removing the shield; and, after removingthe shield, contacting the sieve with an oxygenate feedstock underconditions effective to produce an olefin product, wherein the activatedsieve contacting the oxygenate feedstock has a methanol uptake index ofat least 0.15, preferably 0.4, more preferably at least 0.6, and mostpreferably at least 0.8.

In another embodiment, there is provided a method of making an olefinproduct from an oxygenate feedstock, comprising removing a template froma silicoaluminophosphate molecular sieve and contacting the molecularsieve with the oxygenate feedstock under conditions effective to convertthe feedstock to an olefin product before the methanol uptake indexdrops below 0.15, preferably 0.4, more preferably 0.6, most preferably0.8.

It is desirable that the activated molecular sieve that is contactedwith oxygenate feedstock have a methanol conversion of at least 10 wt. %at a standard time on stream (TOS) of 5 minutes and a weight hourlyspace velocity (WHSV) of 25 hr⁻¹. Preferably the molecular sieve shouldhave a methanol conversion of at least 15 wt. % at a standard time onstream of 5 minutes and a WHSV of 25 hr⁻¹, more preferably a methanolconversion of at least 20 wt. % at a standard time on stream of 5minutes and a WHSV of 25 hr⁻¹.

The shield can be removed ex situ (outside the reactor per se) or insitu. In a preferred embodiment, the shield is the template and thetemplate is removed outside of the reactor unit per se in order tominimize product contamination, particularly nitrogen contamination dueto nitrogen components within a nitrogen-containing template that may beused as the shield.

In another preferred embodiment, once the shield has been removed, themolecular sieve can be maintained at a temperature of at least 150° C.,with no shield, with little if any catalyst activity loss due toexposure of catalytic sites with moisture. In this embodiment, themolecular sieve is preferably maintained at a temperature of 150 to 800°C., more preferably at a temperature of 175-600° C., and most preferablyat a temperature of 200-500° C. in order to maintain catalyst activity.

Preferably, the template is a nitrogen-containing hydrocarbon.Preferably, the nitrogen-containing hydrocarbon is selected from thegroup consisting of a tetraethyl ammonium hydroxide salt,cyclopentylamine, aminomethyl cyclohexane, piperidine, triethylamine,cyclohexylamine, tri-ethyl hydroxyethylamine, morpholine, dipropylamine,pyridine, isopropylamine and mixtures thereof The silicoaluminophosphatemolecular sieve is preferably selected from the group consisting ofSAPO-5, SAPO-8, SAPO-11, SAPO-16, SAPO-17, SAPO-18, SAPO-20, SAPO-31,SAPO-34, SAPO-35, SAPO-36, SAPO-37, SAPO-40, SAPO-41, SAPO-42, SAPO-44,SAPO-47, SAPO-56, metal containing forms thereof, and mixtures thereof.

The oxygenate feedstock is preferably selected from the group consistingof methanol; ethanol; n-propanol; isopropanol; C₄-C₂₀ alcohols; methylethyl ether; dimethyl ether; diethyl ether; di-isopropyl ether;formaldehyde; dimethyl carbonate; dimethyl ketone; acetic acid; andmixtures thereof. More preferably, the oxygenate feedstock is methanolor dimethyl ether.

The silicoaluminophosphate molecular sieve can provided with a bindermaterial, and the template can be removed by heating at a temperaturebetween 200° C. and 800° C. In order to convert the oxygenate to olefinproduct, the process is preferably performed at a temperature between200° C. and 700° C.

The present invention will be better understood by reference to theDetailed Description of the Invention when taken together with theattached drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows methanol conversion using a morpholine based molecularsieve, which has been aged under various environmental conditions;

FIG. 2 shows methanol uptake of a morpholine based molecular sieve; and

FIG. 3 shows methanol conversion using a SAPO-34 molecular sieve whichhas been stored under various conditions.

DETAILED DESCRIPTION OF THE INVENTION

SAPO catalysts, in particular, are susceptible to structural changes asa result of continued exposure to even low levels of moisture. Suchauthorities as Paulitz et al., Microporous Materials, 2, 223-228 (1994),however, have shown through X-ray diffration (XRD), nuclear magneticresonance (NMR), infrared (IR) and nitrogen (N₂) adsorption analysesthat the structural change is largely reversible. Nevertheless, we havefound that although adsorption analyses indicate that structural changeis largely reversible, this data cannot be relied upon as an indicatorof loss of catalytic activity. In particular, we have found that SAPOmolecular sieves lose catalytic activity when the catalytic sites areexposed to an open air environment for as little as a few hours afteractivation, and that loss of catalytic activity is irreversible after acertain point.

The possibility of irreversible loss of catalytic activity presents aproblem in the commercial production-to-use chain where storage andtransport of molecular sieve and catalyst can be over a relatively longperiod of time. For example, the as manufactured molecular sieve can bestored anywhere from 12 hours to many months, perhaps as long as oneyear, before its final use as an activated catalyst.

SAPO molecular sieve, as well as the SAPO molecular sieve blended withother catalyst material, can be protected from negative effects ofmoisture by properly shielding catalytic sites within the molecularsieve. Proper shielding can be accomplished in a variety of ways. Thecatalytic sites can be shielded by maintaining a template within themolecular sieve, by covering the sites with a carbonaceous material orby maintaining the sieve, even without a template, in an anhydrousenvironment. Removing template or carbonaceous material from the activesites of the molecular sieve results in an activated molecular sieve,meaning that the molecular sieve has its catalytic sites open and readyto contact feedstock. The anhydrous environment serves as a shield forthe activated molecular sieve in the sense that it shields activecatalyst sites from contact with open air conditions, particularlymoisture in the air.

In order to use the SAPO molecular sieve as a catalyst, the shield mustbe removed such that the catalytic sites of the molecular sieve can beopen to contact feedstock. Once the shield is removed, however, thecatalytic sites are open to contact with moisture or other componentsthat may be present in the localized environment and cause a loss ofcatalytic activity. Extended exposure of catalytic sites to suchconditions generally results in irreversible loss of catalytic activityto the exposed site. At a certain point, the molecular sieve is not ofpractical use in a large scale catalytic process. As defined herein, alarge scale catalytic process is one having a reactor loading in excessof 50 kg, particularly one having a reactor system loading in excess of500 kg, especially one having a reactor loading in excess of 5000 kg.

Extended exposure, or the point at which loss of catalytic activitybecomes undesirable, is defined according to this invention by amethanol uptake index. According to this invention, the methanol uptakeindex is defined as the ratio between the maximum methanol adsorptioncapacity (wt %) of an activated SAPO molecular sieve (i.e., the initialmethanol adsorption capacity) and the methanol adsorption capacity (wt%) of the activated SAPO molecular sieve at the time of catalyticcontact with a feedstock (i.e., the methanol adsorption capacity at feedcontact). At the time of catalytic contact with a feedstock marks theend of the production-to-use chain.

At the time of catalytic contact means the point in time when theactivated SAPO molecular sieve is contacted with feed under conditionseffective to convert the feed to product, the product containingmeasurable portions of ethylene and propylene. This does not imply,however, that the methanol adsorption capacity at feed contact must becalculated at the exact instant that feed contacts activated molecularsieve. This is because it may not be possible to run such a precisecalculation, particularly in evaluating large scale reaction systems.Therefore, the methanol adsorption capacity at feed contact must beevaluated as soon as practical before contact with feed. For molecularsieve activated in situ, the time between activation and actual contactwith feed is short enough such that the initial methanol adsorptioncapacity is essentially equivalent to the methanol adsorption capacityat feed contact, resulting in a methanol uptake index ofapproximately 1. For ex situ activation, the methanol adsorptioncapacity at feed contact should be evaluated as close as practical toactual contact with feed under catalytic conversion conditions. Undersome circumstances, especially when dealing with large scale systems, asclose as practical may extend up to as much as 12 hours betweenactivation and actual contact with feed under catalytic conversionconditions.

According to this invention, it is preferred that the methanol uptakeindex be at least 0.15, preferably at least 0.4, more preferably atleast 0.6, and most preferably at least 0.8. Although some catalyticactivity can occur at a methanol uptake index below 0.15, the molecularsieve at that state is not of practical value as a commercial scalecatalyst. Irreversible loss of catalytic activity will likely occurbelow this point to the extent that the catalyst is no longer of benefitin a large scale catalytic process.

The catalytic activity of the molecular sieve for use as a catalyst forconverting oxygenate to olefin product is considered sufficientlypreserved or protected when the molecular sieve has the desired methanoluptake index at time of contact with oxygenate under conditionseffective to convert the oxygenate to olefin product. Since the methanoluptake index will drop over time if the molecular sieve is improperlyhandled, contact with oxygenate under reaction conditions should occurbefore the methanol uptake index drops below 0.15.

To calculate methanol uptake index, methanol adsorption capacity must bemeasured. Techniques for measuring methanol adsorption capacity areknown to those of ordinary skill in the art. In a preferred technique,about 5 mg of sample is introduced into a thermogravimetric analyzer(TGA). The sample is subjected to a heat treatment process, whichincludes: (1) heating from room temperature to 450° C., with a heat uprate of 20° C./min. in air; (2) holding at 450° C. for 40 min. in air;and cooling to 30° C. in air. After the sample has reached 30° C., theair flow is switched to a methanol containing nitrogen flow with amethanol partial pressure of 0.09 atm. The sample is contacted with thisnitrogen/methanol mixture for 180 minutes. The methanol adsorptioncapacity is the weight percent weight increase after the 180 minutescontact with the methanol vapor.

To obtain a SAPO molecular sieve having the appropriate methanol uptakeindex, the shield can be removed in situ. That is, the shield, whethertemplate, carbonaceous material or anhydrous liquid or gas, can beremoved inside the reactor or the regenerator during operation. However,in a preferred embodiment, the template or carbonaceous material isremoved ex situ. This means that it is preferred to activate thecatalytic sites of the molecular sieve outside of the reactor. This isbecause there is less likelihood that the shield material willcontaminate the reaction products. This is particularly beneficial whenthe desired product of the methanol reaction process is to be very lowin any nitrogen or sulfur-containing contaminants. For example, in caseswhere the shield is a molecular sieve template containing a nitrogencomponent and the desired product of the reaction process is ethylene,it may be desirable to remove the template ex situ since the presence ofvery small amounts of nitrogen in the ethylene might adversely impactthe subsequent conversion of the ethylene product to polyethylene. Inless sensitive reaction systems, however, catalyst containing a templatematerial can be added as makeup and activated in situ. Even in moresensitive reaction processes, makeup addition can be directly to thereactor, i.e., in situ addition, since makeup addition can be controlledto add catalyst at relatively low quantities over a period of time,thereby minimizing possible product contamination. Preferably, themakeup addition is directly to a return line which sends regeneratedcatalyst from the regenerator back to the reactor, or addition is to theregenerator itself. Addition of catalyst outside of the reactor itselfis considered ex situ addition, which includes addition at the returnline or the regenerator.

When ex situ activation of the molecular sieve is carried out, it isimportant to not let the methanol uptake index drop below the desirablevalue of 0.15, preferably 0.4, more preferably 0.6, and most preferably0.8, before using the molecular sieve in a reaction process. Asmentioned above, this is because irreversible loss of catalyticactivity, which is represented by a significant drop in methanol uptakeindex as well as methanol conversion, will reach a level that isundesirable for practical operation.

It has also been found that once the activated catalyst is loaded into aheated system, whether reactor, regenerator or any other part of theoperating system, or any type of storage environment, loss of catalystactivity is greatly reduced, even when a shield is not present. At atemperature of at least about 150° C., catalyst activity has been foundto be stabilized. This means that at a temperature of 150° C. or above,moisture has very little impact on active catalyst sites. It ispreferred to maintain active molecular sieve at a temperature of 150 to800° C., more preferably at a temperature of 175-600° C., and mostpreferably at a temperature of 200-500° C. in order to maintain catalystactivity.

Undesirable drops in methanol uptake index can be controlled by properhandling during storage or transport. In environments maintained below150° C., this means that as long as there is sufficient shielding of thecatalytic sites before use in a catalytic process, catalytic activitywill be acceptable. Sufficient shielding can be maintained by storing ortransporting the molecular sieve or catalyst containing the molecularsieve with its template or with an acceptable carbonaceous materialwhich shields the catalytic sites from contact with moisture. Even whenactivated, sufficient shielding can be maintained by storing ortransporting the activated molecular sieve or catalyst containing themolecular sieve in an anhydrous environment.

It is also preferable that the activated SAPO molecular sieve have amethanol conversion of at least 10 wt. %, preferably at least 15 wt. %,most preferably at least 20 wt. %, at standard methanol conversionconditions. For purposes of this invention, standard methanol conversionconditions means that methanol conversion is determined at a time onstream (TOS) of 5 minutes and a WHSV of 24 hr⁻¹. As defined herein,methanol conversion is the weight percent of methanol converted toproduct, with any dimethyl ether present in the product not beingincluded as part of the converted product. The method for calculatingmethanol conversion is carried out using a standard ½″ diameter SS,fixed bed, continuous reactor. A sample of the molecular sieve or acatalyst containing the molecular sieve is added to the reactor and 100%methanol is added as feed. The reaction is carried out at 450° C., areactor pressure of 25 psig (i.e., a methanol partial pressure of 25psig), and a weight hourly space velocity (WHSV) of 25 hr⁻¹. Thereaction products are preferably analyzed with an on-line gaschromatograph (GC). After 5 minutes time on stream (i.e., after 5minutes of contacting methanol with molecular sieve under reactionconditions), methanol conversion is calculated as: 100−(wt. %methanol+wt. % DME) left in the product.

In testing for the methanol conversion, WHSV is defined as the weight ofthe feed fed to the ½″ reactor over time (per hour) divided by theweight of the silicoaluminophosphate molecular sieve component of thecatalyst in the reactor. The silicoaluminophosphate molecular sievecomponent of the catalyst is intended to mean only thesilicoaluminophosphate molecular sieve portion that is contained withinthe catalyst. This excludes catalyst components such asnon-silicoaluminophosphate molecular sieves, binders, diluents, inerts,rare earth components, etc.

The silicoaluminophosphate molecular sieves of this invention comprise athree-dimensional microporous crystal framework structure of [SiO₂],[AlO₂] and [PO₂] tetrahedral units. The way Si is incorporated into thestructure can be determined by ²⁹Si MAS NMR. See Blackwell and Patton,J. Phys. Chem., 92, 3965 (1988). The desired SAPO molecular sieves willexhibit one or more peaks in the ²⁹Si MAS NMR, with a chemical shift[(Si) in the range of −88 to −94 ppm and with a combined peak area inthat range of at least 20% of the total peak area of all peaks with achemical shift [(Si) in the range of −88 ppm to −115 ppm, where the[(Si) chemical shifts refer to external tetramethylsilane (TMS).

Silicoaluminophosphate molecular sieves are generally classified asbeing microporous materials having 8, 10, or 12 membered ringstructures. These ring structures can have an average pore size rangingfrom about 3.5-15 angstroms. Preferred are the small pore SAPO molecularsieves having an average pore size ranging from about 3.5 to 5angstroms, more preferably from 4.0 to 5.0 angstroms. These preferredpore sizes are typical of molecular sieves having 8 membered rings.

In general, silicoaluminophosphate molecular sieves comprise a molecularframework of corner-sharing [SiO₂], [AlO₂], and [PO₂] tetrahedral units.This type of framework is effective in converting various oxygenatesinto olefin products.

The [PO₂] tetrahedral units within the framework structure of themolecular sieve of this invention can be provided by a variety ofcompositions. Examples of these phosphorus-containing compositionsinclude phosphoric acid. organic phosphates such as triethyl phosphate,and aluminophosphates. The phosphorous-containing compositions are mixedwith reactive silicon and aluminum-containing compositions under theappropriate conditions to form the molecular sieve.

The [AlO₂] tetrahedral units within the framework structure can beprovided by a variety of compositions. Examples of thesealuminum-containing compositions include aluminum alkoxides such asaluminum isopropoxide, aluminum phosphates, aluminum hydroxide, sodiumaluminate, and pseudoboehmite. The aluminum-containing compositions aremixed with reactive silicon and phosphorus-containing compositions underthe appropriate conditions to form the molecular sieve.

The [SiO₂] tetrahedral units within the framework structure can beprovided by a variety of compositions. Examples of thesesilicon-containing compositions include silica sols and siliciumalkoxides such as tetra ethyl orthosilicate. The silicon-containingcompositions are mixed with reactive aluminum and phosphorus-containingcompositions under the appropriate conditions to form the molecularsieve.

Substituted SAPOs can also be used in this invention. These compoundsare generally known as MeAPSOs or metal-containingsilicoaluminophosphates. The metal can be alkali metal ions (Group IA),alkaline earth metal ions (Group IIA), rare earth ions (Group IIIB,including the lanthanoid elements: lanthanum, cerium, praseodymium,neodymium, samarium, europium, gadolinium, terbium, dysprosium, holmium,erbium, thulium, ytterbium and lutetium; and scandium or yttrium) andthe additional transition cations of Groups IVB, VB, VIB, VIIB, VIIIB,and IB.

Preferably, the Me represents atoms such as Zn, Mg, Mn, Co, Ni, Ga, Fe,Ti, Zr, Ge, Sn, and Cr. These atoms can be inserted into the tetrahedralframework through a [MeO₂] tetrahedral unit. The [MeO₂] tetrahedral unitcarries a net electric charge depending on the valence state of themetal substituent. When the metal component has a valence state of +2,+3, +4, +5, or +6, the net electric charge is between −2 and +3.Incorporation of the metal component is typically accomplished addingthe metal component during synthesis of the molecular sieve. However,post-synthesis ion exchange can also be used.

Suitable silicoaluminophosphate molecular sieves include SAPO-5, SAPO-8,SAPO-11, SAPO-16, SAPO-17, SAPO-18, SAPO-20, SAPO-31, SAPO-34, SAPO-35,SAPO-36, SAPO-37, SAPO-40, SAPO-41, SAPO-42, SAPO-44, SAPO-47, SAPO-56,the metal containing forms thereof, and mixtures thereof Preferred areSAPO-18, SAPO-34, SAPO-35, SAPO-44, and SAPO-47, particularly SAPO-18and SAPO-34, including the metal containing forms thereof, and mixturesthereof. As used herein, the term mixture is synonymous with combinationand is considered a composition of matter having two or more componentsin varying proportions, regardless of their physical state.

The silicoaluminophosphate molecular sieves are synthesized byhydrothermal crystallization methods generally known in the art. See,for example, U.S. Pat. Nos. 4,440,871; 4,861,743; 5,096,684; and5,126,308, the methods of making of which are fully incorporated hereinby reference. A reaction mixture is formed by mixing together reactivesilicon, aluminum and phosphorus components, along with at least onetemplate. Generally the mixture is sealed and heated, preferably underautogenous pressure, to a temperature of at least 100° C., preferablyfrom 100-250° C., until a crystalline product is formed. Formation ofthe crystalline product can take anywhere from around 2 hours to as muchas 2 weeks. In some cases, stirring or seeding with crystalline materialwill facilitate the formation of the product.

Typically, the molecular sieve product will be formed in solution. Itcan be recovered by standard means, however, such as by centrifugationor filtration. The product can also be washed, recovered by the samemeans and dried.

As a result of the crystallization process, the recovered sieve containswithin its pores at least a portion of the template used in making theinitial reaction mixture. The crystalline structure essentially wrapsaround the template, and the template must be removed to obtaincatalytic activity. Once the template is removed, the crystallinestructure that remains has what is typically called an intracrystallinepore system.

The SAPO molecular sieve can contain one or more templates. Templatesare structure directing agents, and typically contain nitrogen,phosphorus, oxygen, carbon, hydrogen or a combination thereof, and canalso contain at least one alkyl or aryl group, with 1 to 8 carbons beingpresent in the alkyl or aryl group. Mixtures of two or more templatescan produce mixtures of different sieves or predominantly one sievewhere one template is more strongly directing than another.

Representative templates include tetraethyl ammonium salts,cyclopentylamine, aminomethyl cyclohexane, piperidine, triethylamine,cyclohexylamine, tri-ethyl hydroxyethylamine, morpholine, dipropylamine(DPA), pyridine, isopropylamine and combinations thereof. Preferredtemplates are triethylamine, cyclohexylamine, piperidine, pyridine,isopropylamine, tetraethyl ammonium salts, and mixtures thereof. Thetetraethylammonium salts include tetraethyl ammonium hydroxide (TEAOH),tetraethyl ammonium phosphate, tetraethyl ammonium fluoride, tetraethylammonium bromide, tetraethyl ammonium chloride, tetraethyl ammoniumacetate. Preferred tetraethyl ammonium salts are tetraethyl ammoniumhydroxide and tetraethyl ammonium phosphate.

In this invention, the templates can be used to shield the catalyticsites of the SAPO molecular sieve from contact with water molecules.Since the templates will be present within the microporous structure ofthe sieve, water molecules will not be able to enter the pores of thesieve, preventing any contact with the catalyst sites. This means that amolecular sieve containing a template can even be stored in wet filtercake form, without noticeable loss of catalytic activity once activated.When stored in wet filter cake form, the molecular sieve will typicallybe dried without removing the template. Then, the molecular sieve can becalcined to remove the template.

Carbonaceous material can also be used to shield the catalytic sites ofthe SAPO molecular sieve. In this embodiment, carbonaceous material canbe within the microcrystalline pore structure or it can be deposited tocover the pore entrance. The carbonaceous material can be placed withinthe crystalline pore structure by partially burning the templatematerial so that carbon residue remains within the molecular sieve.Carbonaceous material can also be directly applied to the exterior ofthe molecular sieve to block the pore openings.

As is known in the art, molecular sieve or catalyst containing themolecular sieve, must be activated prior to use in a catalytic process.Activation is performed in such a manner that template is removed fromthe molecular sieve, leaving active catalytic sites with the microporouschannels of the molecular sieve open for contact with feed. Theactivation process is typically accomplished by calcining, oressentially heating the template at a temperature of from 200 to 800° C.in the presence of an oxygen-containing gas. In some cases, it may bedesirable to heat in an environment having a low oxygen concentration.This type of process can be used for partial or complete removal of thetemplate from the intracrystalline pore system. In other cases,particularly with smaller templates, complete or partial removal fromthe sieve can be accomplished by conventional desorption processes suchas those used in making standard zeolites.

Once the molecular sieve or catalyst containing the molecular sieve hasbeen activated, an anhydrous environment can be provided as a shieldagainst water molecules contacting catalyst sites within the molecularsieve. Such an environment can be provided by covering the sieve with agas or liquid blanket under anhydrous conditions. As provided herein,the anhydrous gas or liquid blanket will have a limited amount of water.The anhydrous gas blanket can be provided under vacuum conditions orunder atmospheric or greater pressure conditions, and will have lessthan about 1.2 volume percent water, preferably less than about 0.2volume percent water, more preferably less than about 0.02 volumepercent water. The anhydrous liquid blanket will have less than about200 ppm water preferably less than about 100 ppm water, more preferablyless than about 50 ppm water. The anhydrous environment can be appliedduring storage, transport or loading of the catalyst.

The anhydrous gas blanket is one which is a gas under standardtemperature and pressure conditions and does not react to anysignificant degree with the molecular sieve structure. The gas ispreferably selected from the group consisting of nitrogen, helium, CO,CO₂, H₂, argon, O₂, light alkanes (especially C₁-C₄ alkanes,particularly methane and ethane), cyclo-alkanes and mixtures thereof,e.g. air. The gas blanket can be maintained at any pressure, includingunder vacuum or at pressures above standard, even if the gas becomesliquid at pressures above standard, as long as the conditions remainanhydrous.

The anhydrous liquid blanket is a liquid under standard temperature andpressure conditions, and does not react to any significant degree withthe molecular sieve structure. The liquid is preferably selected fromthe group consisting of alkanes, cyclo-alkanes, C₆-C₃₀ aromatics,alcohols, particularly C₄ ⁺ branched alcohols.

In this invention, the molecular sieve is made ready for use in acatalytic process by removing the shielding conditions. If the gas orliquid blanket is applied under anhydrous conditions to shield analready activated molecular sieve, the blanket or liquid need merely beremoved by any standard technique. This can be as simple as merelyopening the blanketed system to the atmosphere or by using any standardfiltration or separation technique.

If a carbonaceous material is used as the shield, it can also be removedby exposing the sieve to sufficient temperature conditions to decomposethe carbonaceous material. Preferably, the carbonaceous material isremoved by calcining at a temperature of about 200-800° C.

It is preferred that the molecular sieve not be exposed to hydrousconditions once the shield is removed. Otherwise, there may beirreversible catalytic loss. However, the molecular sieve can be stored,transported or loaded into a reactor system, in its unshielded form, ina hydrous environment as long as the methanol uptake index does not fallbelow 0.15, preferably 0.4, more preferably 0.6, most preferably 0.8.

The silicoaluminophosphate molecular sieves may be admixed (blended)with other materials. When blended, the resulting composition istypically referred to as a silicoaluminophosphate (SAPO) catalyst, withthe catalyst comprising the SAPO molecular sieve.

Materials which can be blended with the molecular sieve can be variousinert or catalytically active materials, or various binder materials.These materials include compositions such as kaolin and other clays,various forms of rare earth metals, other non-zeolite catalystcomponents, zeolite catalyst components, alumina or alumina sol,titania, zirconia, quartz, silica or silica or silica sol, and mixturesthereof. These components are also effective in reducing overallcatalyst cost, acting as a thermal sink to assist in heat shielding thecatalyst during regeneration, densifying the catalyst and increasingcatalyst strength. When blended with non-silicoaluminophosphatemolecular sieve materials, the amount of molecular sieve which iscontained in the final catalyst product ranges from 10 to 90 weightpercent of the total catalyst, preferably 30 to 70 weight percent of thetotal catalyst.

In one embodiment of this invention, a feed containing an oxygenate iscontacted in a reaction zone of a reactor apparatus with an activatedmolecular sieve catalyst at process conditions effective to producelight olefins, i.e., an effective temperature, pressure, WHSV (weighthour space velocity) and, optionally, an effective amount of diluent,correlated to produce light olefins. Typically, the oxygenate feed iscontacted with the catalyst when the oxygenate is in a vapor phase.However, the process may be carried out in a liquid or a mixedvapor/liquid phase. When the process is carried out in a liquid phase ora mixed vapor/liquid phase, different conversions and selectivities offeed-to-product may result depending upon the catalyst and reactionconditions.

Olefins can generally be produced at a wide range of temperatures. Aneffective operating temperature range can be from about 200° C. to 700°C. At the lower end of the temperature range, the formation of thedesired olefin products may become markedly slow. At the upper end ofthe temperature range, the process may not form an optimum amount ofproduct. An operating temperature of at least 300° C., and up to 500° C.is preferred.

Owing to the nature of the process, it may be desirable to carry out theprocess of the present invention by use of the molecular sieve catalystsin a dynamic bed system or any system of a variety of transport bedsrather than in a fixed bed system. It is particularly desirable tooperate the reaction process at high space velocities.

The conversion of oxygenates to produce light olefins may be carried outin a variety of large scale catalytic reactors, including, but notlimited to, fluid bed reactors and concurrent riser reactors asdescribed in “Free Fall Reactor,” Fluidization Engineering, D. Kunii andO. Levenspiel, Robert E. Krieger Publishing Co. NY, 1977, incorporatedin its entirety herein by reference. Additionally, countercurrent freefall reactors may be used in the conversion process. See, for example,U.S. Pat. No. 4,068,136 and “Riser Reactor”, Fluidization andFluid-Particle Systems, pages 48-59, F. A. Zenz and D. F. Othmo,Reinhold Publishing Corp., NY 1960, the descriptions of which areexpressly incorporated herein by reference.

Any standard commercial scale reactor system can be used, includingfixed bed or moving bed systems. The commercial scale reactor systemscan be operated at a weight hourly space velocity (WHSV) of from 1 hr⁻¹to 1000 hr⁻¹. In the case of commercial scale reactors, WHSV is definedas the weight of hydrocarbon in the feed per hour per weight ofsilicoaluminophosphate molecular sieve content of the catalyst. Thehydrocarbon content will be oxygenate and any hydrocarbon which mayoptionally be combined with the oxygenate. The silicoaluminophosphatemolecular sieve content is intended to mean only thesilicoaluminophosphate molecular sieve portion that is contained withinthe catalyst. This excludes components such as binders, diluents,inerts, rare earth components, etc.

It is highly desirable to operate at a temperature of at least 300° C.and a Temperature Corrected Normalized Methane Sensitivity (TCNMS) ofless than about 0.016, preferably less than about 0.012, more preferablyless than about 0.01. It is particularly preferred that the reactionconditions for making olefin from oxygenate comprise a WHSV of at leastabout 20 hr⁻¹ producing olefins and a TCNMS of less than about 0.016.

As used herein, TCNMS is defined as the Normalized Methane Selectivity(NMS) when the temperature is less than 400° C. The NMS is defined asthe methane product yield divided by the ethylene product yield whereineach yield is measured on, or is converted to, a weight % basis. Whenthe temperature is 400° C. or greater, the TCNMS is defined by thefollowing equation, in which T is the average temperature within thereactor in ° C.:

${TCNMS} = \frac{NMS}{1 + \left( {\left( {\left( {T - 400} \right)/400} \right) \times 14.84} \right)}$

The pressure also may vary over a wide range, including autogenouspressures. Effective pressures may be in, but are not necessarilylimited to, pressures of from about 0.1 kPa to about 10 MPa. Preferredpressures are in the range of about 5 kPa to about 5 MPa, with the mostpreferred range being of from about 50 kPa to about 0.5 MPa. Theforegoing pressures are exclusive of any oxygen depleted diluent, andthus, refer to the partial pressure of the oxygenate compounds and/ormixtures thereof with feedstock. At the lower and upper end of theforegoing pressure ranges, the rate of selectivity, conversion and/orreaction may not be optimum.

One or more inert diluents may be present in the feedstock, for example,in an amount of from 1 to 99 molar percent, based on the total number ofmoles of all feed and diluent components fed to the reaction zone (orcatalyst). Typical diluents include, but are not necessarily limited tohelium, argon, nitrogen, carbon monoxide, carbon dioxide, hydrogen,water, paraffins, alkanes (especially methane, ethane, and propane),alkylenes, aromatic compounds, and mixtures thereof. The preferreddiluents are water and nitrogen. Water can be injected in either liquidor vapor form.

The process may be carried out in a batch, semi-continuous or continuousfashion. The process can be conducted in a single reaction zone or anumber of reaction zones arranged in series or in parallel.

The level of conversion of the oxygenates can be maintained to reducethe level of unwanted by-products. Conversion can also be maintainedsufficiently high to avoid the need for commercially undesirable levelsof recycling of unreacted feeds. A reduction in unwanted by-products isseen when conversion moves from 100 mol % to about 98 mol % or less.Recycling up to as much as about 50 mol % of the feed is commerciallyacceptable. Therefore, conversions levels which achieve both goals arefrom about 50 mol % to about 98 mol % and, desirably, from about 85 mol% to about 98 mol %. However, it is also acceptable to achieveconversion between 98 mol % and 100 mol % in order to simplify therecycling process. Oxygenate conversion may be maintained at this levelusing a number of methods familiar to persons of ordinary skill in theart. Examples include, but are not necessarily limited to, adjusting oneor more of the following: the reaction temperature; pressure; flow rate(i e., WHSV); level and degree of catalyst regeneration; amount ofcatalyst re-circulation; the specific reactor configuration; the feedcomposition; and other parameters which affect the conversion.

If regeneration is required, the molecular sieve catalyst can becontinuously introduced as a moving bed to a regeneration zone where itcan be regenerated, such as for example by removing carbonaceousmaterials or by oxidation in an oxygen-containing atmosphere. In apreferred embodiment, the catalyst is subject to a regeneration step byburning off carbonaceous deposits accumulated during the conversionreactions.

The oxygenate feedstock comprises at least one organic-compound whichcontains at least one oxygen atom, such as aliphatic alcohols, ethers,carbonyl compounds (aldehydes, ketones, carboxylic acids, carbonates,esters and the like), and the feedstock may optionally contain at leastone compound containing a halide, mercaptan, sulfide, or amine, as longas the optional components do not significantly impede the performanceof the catalyst. When the oxygenate is an alcohol, the alcohol caninclude an aliphatic moiety having from 1 to 10 carbon atoms, morepreferably from 1 to 4 carbon atoms. Representative alcohols include butare not necessarily limited to lower straight and branched chainaliphatic alcohols, their unsaturated counterparts and the nitrogen,halogen and sulfur analogues of such. Examples of suitable oxygenatecompounds include, but are not limited to: methanol; ethanol;n-propanol; isopropanol; C₄-C₂₀ alcohols; methyl ethyl ether; dimethylether; diethyl ether; di-isopropyl ether; formaldehyde; dimethylcarbonate; dimethyl ketone; acetic acid; and mixtures thereof. Preferredoxygenate compounds are methanol, dimethyl ether, or a mixture thereof.

The method of making the preferred olefin product in this invention caninclude the additional step of making these compositions fromhydrocarbons such as oil, coal, tar sand, shale, biomass and naturalgas. Methods for making the compositions are known in the art. Thesemethods include fermentation to alcohol or ether, making synthesis gas,then converting the synthesis gas to alcohol or ether. Synthesis gas canbe produced by known processes such as steam reforming, autothermalreforming and partial oxidization.

One skilled in the art will also appreciate that the olefins produced bythe oxygenate-to-olefin conversion reaction of the present invention canbe polymerized to form polyolefins, particularly polyethylene andpolypropylene. Processes for forming polyolefins from olefins are knownin the art. Catalytic processes are preferred. Particularly preferredare metallocene, Ziegler/Natta and acid catalytic systems. See, forexample, U.S. Pat. Nos.3,258,455; 3,305,538; 3,364,190; 5,892,079;4,659,685; 4,076,698; 3,645,992; 4,302,565; and 4,243,691, the catalystand process descriptions of each being expressly incorporated herein byreference. In general, these methods involve contacting the olefinproduct with a polyolefin-forming catalyst at a pressure and temperatureeffective to form the polyolefin product.

A preferred polyolefin-forming catalyst is a metallocene catalyst. Thepreferred temperature range of operation is between 50 and 240° C. andthe reaction can be carried out at low, medium or high pressure, beinganywhere within the range of about 1 to 200 bars. For processes carriedout in solution, an inert diluent can be used, and the preferredoperating pressure range is between 10 and 150 bars, with a preferredtemperature range of between 120 and 230° C. For gas phase processes, itis preferred that the temperature generally be within a range of 60 to160° C., and that the operating pressure be between 5 and 50 bars.

This invention will be better understood with reference to the followingexamples, which are intended to illustrate specific embodiments withinthe overall scope of the invention as claimed.

EXAMPLE 1

Samples of SAPO-34 containing a morpholine template were heated in orderto remove the template. One sample was heated for 5 hours at 650° C. inN₂ followed by 3 hours at 650° C. in air in a closed furnace to removethe template. The sample was stored for 4 days over silica gel (relativehumidity <20% at 20° C.). A second sample was heated in the same manner,but was stored for 3 days at 80% relative humidity and 20° C. In a thirdsample, the template was removed in the same manner. However, the thirdsample was transferred at 150° C. into a fixed bed, continuous reactorimmediately after template removal. The third sample was designated asthe “0 days aged” sample portion. Each portion was then individuallyevaluated in a fixed bed, continuous reactor. Reaction temperature wasmaintained at 450° C. Pressure in the reactor was held at 25 psig.Methanol feed was continuously fed to the reactor at a WHSV of 25 hr⁻¹.Reaction products were analyzed with an on-line GC equipped with a FIDand TCD detector. FIG. 1 shows wt % of methanol converted as a functionof TOS (in minutes). The methanol conversion of the first sample at aTOS of 5 minutes was approximately 27 wt. %. The methanol conversion ofthe second sample at a TOS of 5 minutes was approximately 0 wt. %. themethanol conversion of the third sample at TOS of 5 minutes wasapproximately 100 wt. %.

EXAMPLE 2

Samples of SAPO-34 containing a morpholine template were heated in orderto remove the template. One sample was heated for 5 hours at 650° C. inN₂ followed by 3 hours at 650° C. in air in a closed furnace to removethe template. The sample was stored for 1 day under ambient conditions.A second sample was heated in the same manner, but was stored for 5 daysunder ambient conditions. In a third sample, the template was removed insitu (i.e., in a fixed bed, continuous reactor) under nitrogen at 650°C. for 5 hours, followed by air at 650° C. for 3 hours. The third samplewas designated as the “0 days aged” sample portion. The sample portionshaving the templates removed were measured for methanol uptake accordingto the following procedure:

About 5 mg of sample was introduced into a Perkin Elmer TGS-2thermogravimetric analyzer (TGA). The sample was subjected to heattreatment, which included: (1) heating from room temperature to 450° C.,with a heat up rate of 20° C./min. in air; (2) holding at 450° C. for 40min. in air; and cooling to 30° C. in air. After the sample reached 30°C., the air flow was switched to a methanol containing nitrogen flowwith a methanol partial pressure of 0.09 atm. The sample was thencontacted with this nitrogen/methanol mixture for 180 minutes, and themethanol adsorption capacity was calculated as the weight percentincrease after the 180 minutes contact with the methanol vapor. FIG. 2shows methanol adsorption capacity or methanol uptake as a function oftime. The horizontal line fragments indicate the saturation level.

The methanol uptake index was calculated based on the saturation levelaged samples versus the saturation level of the “0 days aged/in situ”sample. The 0 days aged/in situ sample was defined as the base case,having a methanol uptake index of 1. The methanol uptake index for the 1day lab aged sample was calculated as approximately 0.85, and themethanol uptake index for the 5 days lab aged sample was calculated asapproximately 0.65.

EXAMPLE 3

A sample of SAPO-34 containing a DPA/TEAOH template was dried, with thetemplate being left in place. The sample was stored for 25 days, thenmixed with SiC (0.36 g SAPO/5 g SiC). The template was then removed insitu (i.e., in a fixed bed, continuous reactor) under nitrogen at 625°C. for 1 hour. After template removal, methanol was continuously fed tothe reactor at a WHSV of 25 hr⁻¹ while maintaining the reactiontemperature at 450° C. and the reactor pressure at 23 psig. Reactionproducts were analyzed with an on-line GC equipped with a FID and TCDdetector for ethylene and propylene yield. Methanol conversion wascalculated as: 100−(wt % methanol+DME) left in product. The data areshown in FIG. 3, with the label “fresh, calcined sieve.”

EXAMPLE 4

A sample of SAPO-34 containing a DPA/TEAOH template was filtered andstored in a wet filter cake form, with the template being left in place.After storing for 44 days, the filter cake was dried, then the templatewas then removed and methanol conversion calculated according to theprocedure of Example 3. The data are shown in FIG. 3.

EXAMPLE 5

A sample of SAPO-34 containing a DPA/TEAOH template was filtered andstored in a wet filter cake form, with the template being left in place.After storing for 73 days, the filter cake was dried, then the templatewas then removed and methanol conversion calculated according to theprocedure of Example 3. The data are shown in FIG. 3.

EXAMPLE 6

A sample of SAPO-34 containing a DPA/TEAOH template was dried, with thetemplate being left in place. The sample was stored for 132 days underambient conditions. The template was then removed and methanolconversion calculated according to the procedure of Example 3. The dataare shown in FIG. 3.

EXAMPLE 7

A detemplated SAPO-34 was aged under ambient conditions for 18 months.Methanol adsorption capacity was determined according to the procedureof Example 2. From the initial methanol adsorption capacity and themethanol adsorption capacity at feed contact, the methanol uptake indexwas calculated as 0.12.

Methanol conversion of a sample of the 18 months aged SAPO-34 wasevaluated according to the procedure of Example 3. At a TOS of 2minutes, the methanol conversion was 26.97 wt. %. At a TOS of 5 minutes,the methanol conversion had significantly dropped to 0.63 wt. %.

The data indicate that a silicoaluminophosphate molecular sieve having amethanol uptake index of 0.12 is catalytically active for a brief periodof time. However, the catalytic activity of such a molecular sieve dropsoff very quickly, indicating that a molecular sieve having such a lowmethanol uptake index is less desirable for reaction systems, as it willtend to increase the frequency at which the molecular sieve will need tobe regenerated.

Having now fully described this invention, it will be appreciated bythose skilled in the art that the invention can be performed within awide range of parameters within what is claimed, without departing fromthe spirit and scope of the invention.

1. A method of maintaining catalytic activity of an activated SAPOmolecular sieve, comprising: (a) providing a SAPO molecular sieve in aproduction-to-use procedure, wherein the molecular sieve is protectedfrom moisture by shielding catalytic sites within the molecular sieve bymeans of a shield selected from the group consisting of a template, ananhydrous liquid and an anhydrous gas; (b) removing the shield to forman activated molecular sieve; and (c) maintaining the molecular sieve ata temperature of at least 150° C., with no shield, and at a methanoluptake index that does not drop below 0.15 before use of said molecularsieve in an oxygenate to olefin conversion process.
 2. The method ofclaim 1, wherein the shield is a template.
 3. The method of claim 2,wherein the shield is a template and the SAPO molecular sieve is storedin wet filter cake form.
 4. The method of claim 1, wherein the SAPOmolecular sieve, in its unshielded form, is maintained at a temperatureof from 150 to 800° C.
 5. The method of claim 4, wherein the SAPOmolecular sieve, in its unshielded form, is maintained at a temperatureof from 175 to 600° C.
 6. The method of claim 5, wherein the SAPOmolecular sieve, in its unshielded form, is maintained at a temperatureof from 200 to 500° C.
 7. The method of claim 1, wherein the SAPOmolecular sieve, in its unshielded form, is maintained at a methanoluptake index that does not fall below 0.4.
 8. The method of claim 7,wherein the SAPO molecular sieve, in its unshielded form, is maintainedat a methanol uptake index that does not fall below 0.6.
 9. The methodof claim 8, wherein the SAPO molecular sieve, in its unshielded form, ismaintained at a methanol uptake index that does not fall below 0.8. 10.The method of claim 1, wherein the SAPO molecular sieve, in itsunshielded form, is maintained in a reactor, regenerator or storageenvironment.
 11. The method of claim 1, wherein the SAPO molecular sievecomprises molecular sieve selected from the group consisting of SAPO-17,SAPO-18, SAPO-34, SAPO-35, SAPO-44, SAPO-47, SAPO-56, metal containingforms thereof, and mixtures thereof.
 12. A method of maintainingcatalytic activity of an activated SAPO molecular sieve, the methodcomprising: (a) providing a SAPO molecular sieve, wherein the molecularsieve is protected from moisture by shielding catalytic sites within themolecular sieve; (b) removing the shield to form an activated molecularsieve; (c) loading the activated SAPO molecular sieve into a storageenvironment; and (d) maintaining the molecular sieve at a temperature ofat least 150° C., with no shield, and at a methanol uptake index thatdoes not drop below 0.15 before use of said molecular sieve in anoxygenate to olefin conversion process.
 13. The method of claim 12,wherein the shield is a template, carbonaceous material, anhydrousliquid or anhydrous gas.
 14. The method of claim 13, wherein the shieldis a template and the SAPO molecular sieve is stored in wet filter cakeform.
 15. The method of claim 12, wherein the SAPO molecular sieve, inits unshielded form, is maintained at a temperature of from 150 to 800°C.
 16. The method of claim 15, wherein the SAPO molecular sieve, in itsunshielded form, is maintained at a temperature of from 175 to 600° C.17. The method of claim 16, wherein the SAPO molecular sieve, in itsunshielded form, is maintained at a temperature of from 200 to 500° C.18. The method of claim 12, wherein the SAPO molecular sieve, in itsunshielded form, is maintained at a methanol uptake index that does notfall below 0.4.
 19. The method of claim 18, wherein the SAPO molecularsieve, in its unshielded form, is maintained at a methanol uptake indexthat does not fall below 0.6.
 20. The method of claim 19, wherein theSAPO molecular sieve, in its unshielded form, is maintained at amethanol uptake index that does not fall below 0.8.
 21. The method ofclaim 12, wherein the SAPO molecular sieve comprises molecular sieveselected from the group consisting of SAPO-17, SAPO-18, SAPO-34,SAPO-35, SAPO-44, SAPO-47, SAPO-56, metal containing forms thereof, andmixtures thereof.
 22. A method of maintaining catalytic activity of anactivated SAPO molecular sieve, the method comprising: (a) providing aSAPO molecular sieve, wherein the molecular sieve is protected frommoisture by shielding catalytic sites within the molecular sieve; (b)removing the shield to form an activated molecular sieve; (c) loadingthe activated SAPO molecular sieve into a storage environment; and (d)storing or transporting the activated SAPO molecular sieve in ananhydrous environment, and at a methanol uptake index that does not dropbelow 0.15 before use of said molecular sieve in an oxygenate to olefinconversion process.
 23. The method of claim 22, wherein the shield is atemplate, carbonaceous material, anhydrous liquid or anhydrous gas. 24.The method of claim 23, wherein the shield is a template.
 25. The methodof claim 22, wherein the SAPO molecular sieve, in its unshielded form,is maintained at a temperature of from 150 to 800° C.
 26. The method ofclaim 25, wherein the SAPO molecular sieve, in its unshielded form, ismaintained at a temperature of from 175 to 600° C.
 27. The method ofclaim 26, wherein the SAPO molecular sieve, in its unshielded form, ismaintained at a temperature of from 200 to 500° C.
 28. The method ofclaim 22, wherein the SAPO molecular sieve, in its unshielded form, ismaintained at a methanol uptake index that does not fall below 0.4. 29.The method of claim 28, wherein the SAPO molecular sieve, in itsunshielded form, is maintained at a methanol uptake index that does notfall below 0.6.
 30. The method of claim 29, wherein the SAPO molecularsieve, in its unshielded form, is maintained at a methanol uptake indexthat does not fall below 0.8.
 31. The method of claim 22, wherein theSAPO molecular sieve comprises molecular sieve selected from the groupconsisting of SAPO-17, SAPO-18, SAPO-34, SAPO-35, SAPO-44, SAPO-47,SAPO-56, metal containing forms thereof, and mixtures thereof.
 32. Themethod of claim 22, wherein the anhydrous environment is a gas blanketor a liquid blanket.
 33. The method of claim 32, wherein the anhydrousenvironment is a gas blanket.
 34. The method of claim 33, wherein theanhydrous gas blanket has less than 1.2 volume percent water.
 35. Themethod of claim 34, wherein the anhydrous gas blanket has less than 0.2volume percent water.
 36. The method of claim 35, wherein the anhydrousgas blanket has less than 0.02 volume percent water.
 37. A method ofmaintaining catalytic activity of an activated SAPO molecular sieve, themethod comprising: (a) providing a SAPO molecular sieve having catalyticsites protected against loss of catalytic activity by covering with ashield; (b) removing the shield; and (c) storing and transporting aspart of a production-to-use procedure or loading into a reactor system,the SAPO molecular sieve, in its unshielded form, in a hydrousenvironment at a methanol uptake index that does not fall below 0.15,before use of said activated molecular sieve in an oxygenate olefinconversion process.
 38. The method of claim 37, wherein the shield is atemplate, carbonaceous material, anhydrous liquid or anhydrous gas. 39.The method of claim 38, wherein the shield is a template and the SAPOmolecular sieve is stored in wet filter cake form.
 40. The method ofclaim 39, wherein the SAPO molecular sieve, in its unshielded form, doesnot fall below 0.4.
 41. The method of claim 40, wherein the SAPOmolecular sieve, in its unshielded form, does not fall below 0.6. 42.The method of claim 41, wherein the SAPO molecular sieve, in itsunshielded form, does not fall below 0.8.